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Centrifugal FansEnergy Savings and Reduced Wear
Copyright ©Clarage 2010
Introduction• 125 years experience• Specialize in Performance upgrades and
Energy savings• Largest testing facility in U.S.
Copyright ©Clarage 2010
• Lowers plant operating cost• Upgrades plant capacity• Reduce downtime & maintenance cost• Reduces vibration
Why Retrofit Impellers?
Copyright ©Clarage 2010
Why Retrofit Impellers?
Fan Motor Size
Annual Electrical Cost for Typical Utility Rates*
$0.05/kWh $0.10/kWh $.15/kWh50 HP $17,600 $35,200 $52,800
200 HP $68,600 $137,200 $205,800
1000 HP $340,400 $680,800 $1,021,200
Copyright ©Clarage 2010
Retrofit Process – Step 1Test the actual fan and system resistance curve
Copyright ©Clarage 2010
Retrofit Process – Step 1Test the actual fan and system resistance curve
Questions to ask:•Did the fan ever work correctly?•Have you changed anything in the system sinceinstallation?•How much damper do you use?•Is the fan oversized/undersized?
Retrofit Process - Step 2
Copyright ©Clarage 2010
Static efficiency
Impeller design
Select the most efficient fan for the applicationEfficiency and rotor design are linked.
Copyright ©Clarage 2010
Retrofit Process – Step 2Select the most efficient fan for the application
BackwardInclined
Efficiency
Flow
BackwardCurved
Radial Tip
Airfoil
Copyright ©Clarage 2010
Retrofit Process – Step 2
Q:What is (static) efficiency?A:The rate that a fan turns horsepower into staticpressure
Fan Static Efficiency%=Volume x Δp(static pressure)
102 x hp input to fan shaftx 100
Retrofit Process – Step 3
Calculate energy savings and payback
Copyright ©Clarage 2010
Average Retail Price of Electricity to Ultimate Customers by End-Use Sector, by State, August 2010*
Copyright ©Clarage 2010
(Cents per Kilowatthour) 2010New England 11.65
Middle Atlantic 8.44
East North Central 6.82
West North Central 6.56
South Atlantic 7.01
East South Central 6.45
West South Central 6.44
Mountain 6.79
Pacific Contiguous 8.69
Pacific Noncontiguous 20.15
U.S. Total 7.21
*http://www.eia.doe.gov/electricity/epm/table5_6_a.html
Price vs Operating cost
y = 55.578x + 2700.3y = 513.04x - 668.21
$0
$5,000
$10,000
$15,000
$20,000
$25,000
$30,000
$35,000
$40,000
0 200 400 600BHP
Fan PriceOperating CostLinear (Fan Price)Linear (Operating Cost)
Industrial Fan MarketFAN Systems Market Study. A study commissioned by DOEhas estimated that optimizing industrial motor systemsthrough fan system efficiency upgrades can reduce industrialenergy consumption 75 to 122 billion kWh, with a value of$3.6–$5.8 billion at 1994 industrial energy prices. Theseestimates include only the energy savings and do not factorin other benefits likely to result from optimization. Benefitsinclude improved control over production processes, reducedmaintenance, and improved environmental compliance. Thisstudy is based on on-site surveys of 265 industrial facilities inthe United States, in a statistically based sampling of themanufacturing sector.
The study, titled United States Industrial Electric MotorSystems Market Opportunities Assessment, can bedownloaded from the Best Practices Web site.
Sources: Manufacturers Energy Consumption Survey 1994, Bureau of Economic Analysis 1997,Census of Manufacturers 1993, and US Industrial Electric Motor Systems Market OpportunitiesAssessment, US DOE, 1998.
Industrial Fan Market
Case Study 1 - Industrial MarketOverview: Existing fan was oversized and experienced maintenanceissues that effected reliability. Rotor was also oversized, and operated ata damper setting of 65% open. Normal operating conditions shouldrange 70-90% open. Due to the large volume of air required for thepelletizing process, this fan was critical in the overall production of thefacility.
Solution: Clarage conducted field studies of the existing equipment andcustomized a new impeller that was a better fit for the duty point. Thenew impeller was more efficient , and exceeded payback expectations.
Industry:Mining
Location:Mountain Iron, Minnesota
Application:Pelletizing/SteelProduction
Fan Type:Radial Tipped
Case Study 2 - Industrial MarketOverview: The existing fan design of the induced drafts was a forwardcurve design. The impellers experienced salt cake build-up, causingvibration problems. The facility installed a steam injection system to assistreducing the build-up. Testing was conducted to evaluate existing fanperformance for potential impeller re-design and to eliminate the steaminjection system, reduce material build-up and to possibly reduce theoperating cost of the fan with a more efficient impeller design.
Solution: Clarage designed an more efficient backward curved wheel thatincreased the energy efficiency and reduced the annual maintenance andoperating cost.Industry:
Pulp & Paper
Location:Wisconsin Rapids, WI
Application:Recovery Boilers
Fan Type:Induced Draft
Case Study 3 - Industrial MarketOverview: Testing conducted to evaluate existing fan performancefor potential energy savings.
Solution: A new operating point rendered the existing faninefficient. A new rotor design was needed to better suit thecurrent and future needs of the plant. Due to the heavy particulateloading, Clarage used its high efficient cement handling design, andprovided paybacks that were less than 7 months.
Industry:Chemical
Location:Maysville, Kentucky
Application:Kiln Fan
Fan Type:Induced Draft
Case Study 4 - Industrial MarketOverview: An existing airfoil fan was installed at a public utilities plant inthe late 1970’s. The fan was oversized and experienced maintenance issuesthat effected reliability. The fan’s damper settings were set to allow 60% airflow.
Solution: Clarage proposed a smaller impeller to fit into the existinghousing. The smaller impeller had several benefits. First, the fan systemwas more efficient, and consumes less energy. The dampers were now at90% open. Second, the smaller diameter impeller had a reduced tip speed.This lower tip speed reduces the amount of noise pollution in thesurrounding environment.
Industry:Utilities
Location:Manitowac, WI
Application:Circulating FluidizedBeds
Fan Type:Airfoil Centrifugal Fan
